Handle For A Carrying Case

ABSTRACT

A carrying case including a handle-receiving portion having a recess extending along at least one side of the handle-receiving portion, one or more first attachment mechanisms in the recess, a handle including an inner layer and an outer layer, the outer layer including a material having a durometer value less than a durometer value of the handle-receiving portion, wherein the handle is adapted to attach into the recess, and wherein the handle includes one or more second attachment mechanisms for engaging the first attachment mechanisms.

FIELD OF THE INVENTION

This invention relates generally to a blow-molded carrying case, andmore specifically to a blow-molded carrying case with a low durometerhandle to facilitate gripping and transport of the carrying case.

BACKGROUND OF THE INVENTION

The use of blow molding as a method for manufacturing various sorts ofarticles is generally well known. Typically, this process involves theuse of a mold consisting of two separate halves or portions havingcavities of particularly desired shapes and sizes. Usually, one extrudesa large-diameter, sealed tube of molten material (commonly referred toas a “parison”), places the tube between the mold halves, and closes themold around the tube. Fluid pressure is then introduced into the tube,forcing the molten tube against the walls of the cavities, conformingthe tube to the shape thereof. The pressure is maintained until themolten material cools and solidifies. The pressure is then released, themold halves are pulled apart, and the hardened article is ejectedtherefrom.

One such article that is commonly manufactured in this manner iscarrying cases. By producing cases in this manner, one is able toproduce a device that is capable of carrying and protecting tools placedinside the case that has a multitude of desirable physicalcharacteristics—such as rigidity, scuff resistance, and impactabsorption—yet that is relatively inexpensive to manufacture. Typically,these cases will be formed using the process described above, where onemold half forms the exterior of both the base and lid portions of thecase, while the other mold half forms the interior of both base and lidportions. Usually, the mold half forming the exterior of the case formsa wall with a smooth, attractive shape, while the mold half that formsthe interior of the case is often molded with compartments to holdspecific contents, such as, for example, a pistol-type soldering ironand various tips therefore. In fact, a particular advantage ofmanufacturing cases in this way is that the walls formed by the two moldhalves do not need to match, as the space between these walls is filledwith air.

Though such cases are generally well known in the art, efforts have beenmade to increase the carrying capacity of such cases. Many carryingcases have handles to enable the user to more easily pick up, carry, andotherwise maneuver the carrying cases. Most of such cases includehandles that are molded integrally with the body of the case. Suchhandles are usually manufactured of the same rigid material as the case,and thus are not comfortable for gripping and transporting the case,especially if such case is heavy.

Some attempts have been made to provide auxiliary handles. For example,U.S. Pat. No. 4,890,355 to Schulten discloses a hand grip for handles.The handle grip includes an elongated tubular body made of plastic witha longitudinal opening extending along the length of the grip. The handgrip expands over an associated handle. The hand grip disclosed inSchulten, however, does not appear to contain means for a secureattachment to the handle, and does not provide a layer of soft materialto facilitate gripping. Moreover, the hand grip disclosed in Schultenmerely surrounds and does not mount flush on the associated handle.

Therefore, there is a need for a handle for a blow-molded carrying casethat is designed to facilitate comfortable gripping of the handle by auser and is adapted for an easy but secure attachment to the carryingcase.

SUMMARY OF THE INVENTION

Accordingly, it is an objective of the present invention to provide animproved handle for blow molded carrying cases including a low durometermaterial to facilitate comfortable gripping of the handle by a user. Itis a further object to provide a blow molded carrying case adaptable toreceive such handle.

It is a further objection to provide a low durometer handle that mountsflush with the carrying case without any fasteners. It is a furtherobject of the present invention to provide a removeable or replaceablehandle for blow molded carrying cases.

These and other objectives are achieved by providing a handle for acarrying case including a first layer including an outer surface, asecond layer fixedly attached to the outer surface of the first layer,at least one attachment mechanism on the first layer for attachment to acarrying case, wherein the second layer has a durometer value less thana durometer value of the first layer. The handle may be adapted toattach into a recess on the carrying case, wherein a thickness of thehandle is substantially the same as a depth of the recess for flushmounting.

In some embodiments, the attachment mechanism includes at least twolinear protrusions on an inner surface of the first layer, e.g.,substantially opposite to one another extending along longitudinal edgesof the first layer. In some embodiments, an outer surface of the secondlayer includes a plurality of ridges to facilitate gripping of thehandle by a user.

Other objectives are achieved by providing a carrying case including ahandle-receiving portion having a recess extending along at least oneside of the handle-receiving portion, one or more first attachmentmechanisms in the recess, a handle including an inner layer and an outerlayer, the outer layer including a material having a durometer valueless than a durometer value of the handle-receiving portion, wherein thehandle is adapted to attach into the recess, and wherein the handleincludes one or more second attachment mechanisms for engaging the firstattachment mechanisms.

In some embodiments, the handle has a thickness substantially the sameas a depth of the recessed cavity. In further embodiments, the durometervalue of the outer layer is also less than a durometer value of theinner layer.

In some embodiments, the first attachment mechanisms include at leasttwo linear cavities extending along opposite edges of the recess. Thesecond attachment mechanisms may also include at least two linearprotrusions on an inner surface of the inner layer.

In further embodiments, the carrying case further includes a baseportion, the base portion including a base cavity for enclosing at leasta part of at least one object, a lid portion hingedly connected to thebase portion and movable from an open position to a closed position, thelid portion including a lid cavity for enclosing at least a part of atleast the object, wherein at least one of the base portion and the lidportion includes the handle-receiving portion. Each of the base portionand the lid portion may be blow molded.

In some exemplary embodiments, the carrying case further includes atleast one locking mechanism for retaining the lid portion in the closedposition. In some such embodiments, the locking mechanism includes ofthe handle.

Other objects of the invention and its particular features andadvantages will become more apparent from consideration of the followingdrawings and accompanying detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a blow molded carrying case with ahandle in accordance with one exemplary embodiment of the presentinvention.

FIG. 2 is a perspective view of a portion of the carrying case of FIG. 1without the attached handle.

FIG. 3 is a perspective view of the handle for the carrying case shownin FIG. 1.

FIG. 4 is a front view of the handle shown in FIG. 3.

FIGS. 5A-5B illustrate the assembly of the handle and carrying caseshown in FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

The basic components of one embodiment of a blow molded case inaccordance with the invention are illustrated in FIGS. 1-2. As used inthe description, the terms “top,” “bottom,” “above,” “below,” “over,”“under,” “above,” “beneath,” “on top,” “underneath,” “up,” “down,”“upper,” “lower,” “front,” “rear,” “back,” “forward” and “backward”refer to the objects referenced when in the orientation illustrated inthe drawings, which orientation is not necessary for achieving theobjects of the invention.

FIG. 1 illustrates an exemplary carrying case 100. The case 100 includesa base portion 112 and a lid portion 114 connected thereto. The baseportion 112 and lid portion 114 may be blow molded articles formed bysingle or separate blow molding processes. In some embodiments, the lidportion 114 is connected to the base portion 112 via a hinge mechanism120.

The lid portion 114 is movable between open and closed positions, suchthat, when in a closed position, the lid portion 114 is adjacent to baseportion 112 and at least partly covers any objects accommodated in thecase 100. The lid portion 114 and/or base portion 112 may include atleast one clasp (not shown) or other locking mechanism for keeping it inthe closed position. For example, in some embodiments, the handle 150functions as the locking mechanism. In some embodiments, the lid portion114 may include a translucent section for viewing objects contained inthe case 100.

Any of various configurations may be employed for the surface of theinner wall of base portion 112, including various recesses and/or holestherethrough in whatever shapes and sizes as may be appropriate toaccommodate various tools, as well as any other accessories that it maybe desired to carry in the case 100. Various mold planes and punches canbe used to create any variety of through-holes, blind holes, flanges, orsidewalls for accommodating, and providing support for, these variousobjects. Similarly, the lid portion 114 may also include an inner wallwith recesses and/or holes for accommodating the top of the objects whenthe case 100 is closed.

In the exemplary embodiment, the base portion 112 includes ahandle-receiving portion 130 formed integrally with the base portion112. For example, the hand-receiving portion 130 may be blow molded as asingle and/or continuous piece with the base portion 112. However, itshould be understood that in certain embodiments the handle-receivingportion 130 may be formed integrally with the lid portion 114 instead ofthe base portion 112. Alternatively, the handle-receiving portion 130may include two separate portions, one half being formed integrally withthe base portion 112, and the other half being formed integrally withthe lid portion 114. In such embodiments where the handle-receivingportion 130 includes two separate halves, the handle 150 may alsofunction as a locking mechanism. For example, the handle 150 may besnapped into place about each of the two separate halves when the case100 is closed to retain the case 100 in the closed position. To open thecase, the handle 100 may be removed allowing the lid portion 114 andbase portion 112 to separate. In further embodiments of the presentinvention, the handle-receiving portion 130 may be formed separate fromthe case 100 and then connected to the case 100.

FIG. 2 illustrates the handle-receiving portion 130 of the case 100. Thehandle-receiving portion 130 includes a recess or cavity 132 foraccommodating the handle 150. In the exemplary embodiment, the recess132 includes a convex face 134. The handle-receiving portion 130preferably has a depth (e.g., between an outer surface of thehandle-receiving portion and the face 134) approximately equal to athickness of the handle 150 such that the handle 150 is flush with thehandle-receiving portion 130 when in place.

The handle-receiving portion 130 further includes one or more attachmentmechanisms to secure the handle 150 to the case 100. In the exemplaryembodiment, the handle-receiving portion 150 includes two linearcavities 136 extending longitudinally along the face 134 of thehandle-receiving portion 130. The face 134 and the linear cavities 136receive the handle 150 to facilitate gripping of the carrying case 100,as shown in FIG. 1. As described in more detail below, the handle 150 isadapted to slide over the face 134 and snap into place in the recess. Inthe exemplary embodiment, the handle 150 is retained at least in part byengagement with the linear cavities 136. However, in other embodiments,other attachment mechanisms may be employed including but not limited tocircumferential protrusions and cavities, shaped (e.g., square,circular, etc.) protrusions and cavities, or any other suitableattachment or retention mechanisms. In some other embodiments, anadhesive is used between the face 134 and the handle 150.

As shown in FIG. 3, the handle 150 includes a first layer 152 consistingof a semi-rigid material and having an outer surface 154 and an innersurface 156. The handle 150 further includes a second layer 160including a low durometer material securely attached to the outersurface 154 of the first layer 152. In some embodiments, the outersurface 154 of first layer 152 also includes a raised edge (not shown)that circumscribes and is flush with the second layer 160.

The low durometer material of the second layer 160 provides for a softgrip on the handle 150. Durometer may be determined by any number ofscales including but not limited to the American Society for Testing andMaterials (“ASTM”) D2240 type A scale. In preferred embodiments, thesecond layer 160 has a durometer value less than a durometer value ofthe first layer 152 and/or less than a durometer value of the case 100.In some embodiments, the second layer 160 has a durometer value lessthan 100. In some other embodiments, the second layer 160 has adurometer value less than 70 or less than 50.

In the exemplary embodiment, the first layer 152 and the second layer 14have a concave or semicircular shape to fit about the receiving face 134of the handle-receiving portion 130. In the exemplary embodiment, theinner surface 156 of the first layer 152 has at least two linearprotrusions 158 (as shown in FIGS. 3 and 4) opposite in location to eachother and extending along longitudinal edges of the handle 150, e.g., inthe same plane.

The first layer 152 may be made from any type of semi-rigid material,such as a polypropylene and/or plastic, that is sufficiently flexible toextend around the handle-receiving portion 130. The rigidity of thefirst layer 152 may be varied depending on whether it is desired for thehandle to be readily removable, semi-permanent, or permanent. In someembodiments, the handle 150 is removeable from the carrying case 100 bypulling it off the handle-receiving portion 130, causing the protrusions158 to disengage from the linear cavities 132. In other embodiments, thehandle 150 is permanently or semi-permanently attached to the case 100by means of the protrusions 158 and/or other attachment means such asadhesive. The first layer 152 generally includes a constant thickness ofmaterial. However, in some embodiments, the first layer 152 includes aportion of reduced thickness (e.g., extending longitudinally down thecenter of the first layer 152) to create or add to the flexibility ofthe first layer 152.

FIGS. 5A-5B illustrate assembly of the case 100 and handle 150 accordingto the exemplary embodiment. When the handle 150 is pressed into thehandle-receiving portion 130, the handle 150 expands about the face 134.The distance between the linear protrusions 158 increases as the handle150 is pressed onto the handle-receiving portion 130. The linearprotrusions 158 then snap into the corresponding linear cavities 136 onthe handle-receiving portion 130. The protrusions 158 interlock with thelinear cavities 136 and secure the handle 150 to the carrying case 100.

Once in place on the carrying case, the handle 150 is substantiallyflush with the outer surface of the hand-receiving portion 130. Thethickness of the handle 150 is preferably substantially equal to thedepth of the recessed cavity 132 in the handle-receiving portion 130.Thus, the handle 150 has an appearance of being formed together with thecarrying case 100. Moreover, the flush mounting of the handle 150provides a significant improvement in comfort of the handle 150. Thehandle 150 is securely mounted such that the handle 150 does not move orrotate during use. In some embodiments, the second layer 160 may have aplurality of ridges 162 that are circumferential and/or contoured to ashape of a hand to facilitate gripping of the handle by a user. In theexemplary embodiment, the second layer 160 includes three substantiallyparallel ridges 162.

In certain embodiments, the first and the second layers of the handle150 may have a substantially circular shape to extend around ahandle-receiving portion 130 including a circumferential recess 132. Thehandle 150 may have a circumference slightly larger than a circumferenceof the recess 132 to enable the handle 150 to fit around thehandle-receiving portion 130. In such embodiment, the protrusions 158may be located adjacent to each other such as to substantially enclosethe handle-receiving portion 130 of the case 100 when the handle ispressed into the case 100.

It should be understood that the foregoing is illustrative and notlimiting, and that obvious modifications may be made by those skilled inthe art without departing from the spirit of the invention. Accordingly,reference should be made primarily to the accompanying claims, ratherthan the foregoing specification, to determine the scope of theinvention.

1. A handle for a carrying case, comprising: a first layer comprising anouter surface; a second layer fixedly attached to the outer surface ofsaid first layer; at least one attachment mechanism on said first layerfor attachment to a carrying case; wherein the second layer has adurometer value less than a durometer value of the first layer.
 2. Thehandle according to claim 1, wherein said handle is adapted to attachinto a recess on the carrying case, wherein a thickness of said handleis substantially the same as a depth of the recess.
 3. The handleaccording to claim 1, wherein said attachment mechanism comprises atleast two linear protrusions on an inner surface of said first layer. 4.The handle according to claim 3, wherein the two linear protrusions aresubstantially opposite to one another extending along longitudinal edgesof said first layer.
 5. The handle according to claim 1, wherein saidfirst layer comprises a plastic material.
 6. The handle according toclaim 1, wherein an outer surface of said second layer includes aplurality of ridges to facilitate gripping of the handle by a user. 7.The handle according to claim 1, wherein each of said first and secondlayers has a substantially concave shape.
 8. The handle according toclaim 1, wherein each of said first and second layers is substantiallysemicircular.
 9. A carrying case, comprising: a handle-receiving portionhaving a recess extending along at least one side of saidhandle-receiving portion; one or more first attachment mechanisms in therecess; a handle including an inner layer and an outer layer, the outerlayer including a material having a durometer value less than adurometer value of said handle-receiving portion; wherein said handle isadapted to attach into the recess; and wherein the handle includes oneor more second attachment mechanisms for engaging the first attachmentmechanisms.
 10. The carrying case according to claim 9, wherein saidhandle has a thickness substantially the same as a depth of the recess.11. The carrying case according to claim 9, wherein the durometer valueof the outer layer is less than a durometer value of the inner layer.12. The carrying case according to claim 9, wherein said firstattachment mechanisms comprise at least two linear cavities extendingalong opposite edges of the recess.
 13. The carrying case according toclaim 12, wherein said second attachment mechanisms comprise at leasttwo linear protrusions on an inner surface of the inner layer.
 14. Thecarrying case according to claim 9, wherein said handle-receivingportion is blow molded.
 15. The carrying case according to claim 9,further comprising: a base portion, said base portion comprising a basecavity for enclosing at least a part of at least one object; a lidportion hingedly connected to said base portion and movable from an openposition to a closed position, said lid portion comprising a lid cavityfor enclosing at least a part of at least said object; wherein at leastone of said base portion and said lid portion comprises saidhandle-receiving portion.
 16. The carrying case according to claim 15,wherein each of said base portion and said lid portion are blow molded.17. The carrying case according to claim 16, wherein saidhandle-receiving portion is formed integrally with at least one of saidbase portion and said lid portion.
 18. The carrying case according toclaim 16, wherein a first portion of said handle-receiving portion isformed integrally with said base portion and a second portion of saidhandle-receiving portion is formed integrally with said lid portion. 19.The carrying case according to claim 15, further comprising at least onelocking mechanism for retaining said lid portion in the closed position.20. The carrying case according to claim 19, wherein said lockingmechanism consists of said handle.
 21. The carrying case according toclaim 9, wherein said handle-receiving portion includes a substantiallycylindrical portion, wherein the recess extends along at least one sideof the substantially cylindrical portion.
 22. The carrying caseaccording to claim 9, wherein said inner layer of said handle comprisesa plastic material.
 23. The carrying case according to claim 9, whereinsaid outer layer comprises a plurality of ridges to facilitate grippingof said handle by a user.
 24. The carrying case according to claim 9,wherein said inner layer and said outer layer comprise a substantiallycircular shape having a circumference greater than a circumference ofsaid handle-receiving portion such as to enclose said handle-receivingportion when said handle is received in the recess.